ABB low voltage AC drives, wind turbine converters and solar inverters

Capacitor reforming instructions

Converter modules with electrolytic DC capacitors in the DC link
 2012 ABB Oy. All Rights Reserved. 3BFE64059629 Rev E
EN
EFFECTIVE: 2012-03-21
 3

Table of contents

1. Introduction
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ABB low voltage AC drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ABB wind turbine converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ABB solar inverters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
About capacitor reforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
How to check the converter age . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2. Reforming the capacitors

Method 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Method 2 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Method 2 B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Reforming time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Further information
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4
 Introduction 5

1
Introduction

Applicability
This manual applies to converter modules which have electrolytic DC capacitors in the DC
link. The subsections below list the converter module types and product series in more
detail for each product area. All converter module types are referred to as converter or
converter module in this manual.
Note: A drive (module) is used in all connection diagrams. The connection principle is the
same for the other converter module types as well, considering that the terminal markings
may vary.

 ABB low voltage AC drives

This manual applies to drive, inverter, IGBT supply and three-phase brake modules in
product series ACS800, ACS850, ACQ810, ACSM1 and ACS880, ie, the following module
types:
• ACS800-01, -02, -04, -104 and -104LC
• ACS800-11 and ACS800-31
• ACS850-04
• ACQ810-04
• ACSM1-04 and ACSM1-204
• ACS880-01, -04 and -104.

 ABB wind turbine converters

This manual applies to line-side converter modules and generator-side converter modules
in product series ACS800-67LC, ACS800-77LC, ACS800-87LC and ACS800N-87LC.
Note: ACS800-67 and ACS800-77 modules include filmcapacitors in the DC link instead
of electrolytic capacitors.The film capacitors do not need to be reformed.
6 Introduction

 ABB solar inverters

This manual applies to solar inverter modules in product series PVS800-57.

About capacitor reforming

Converter DC link capacitors need to be reformed (re-aged) if the converter has been non-
operational for more than one year. Without reforming, capacitors may get damaged when
the converter starts to operate. It is recommended to reform the capacitors once a year.
Besides the reforming methods presented in this manual, ABB can supply you with ready-
made reforming devices, such as FINERO FST-DCP 1500-05 and FUG HCK 800-2000.
For more information on purchasing these devices, contact your local ABB representative.

How to check the converter age

Converter serial number defines the week when the converter was manufactured:
• 7 digits: For example, in 3260034, 3 denotes manufacturing year (2003), 26
manufacturing week and 0034 running manufacturing number.
• 8 digits: For example, in 14250125, 1 denotes manufacturing country (1 = Finland), 4
manufacturing year (2004), 25 manufacturing week and 0125 running manufacturing
number.
• 10 digits: For example, in 1063200725, 1 denotes manufacturing country, 06
manufacturing year (2006), 32 manufacturing week and 00725 running manufacturing
number.

Safety instructions

WARNING! Neglecting the following instructions may cause physical injury or

death.

• All electrical installation and maintenance work on the converter should be carried out
by qualified electricians only.
• Never work on the converter, motor cable or motor when input power is applied. After
disconnecting the input power, always wait for 5 minutes to let the intermediate circuit
capacitors to discharge before you start working on the converter, the motor or motor
cable.
• Always ensure by measuring with a multimeter (impedance at least 1 Mohm) that:
1. voltage between converter input phases U1, V1 and W1 and the frame is close to
0 V.
2. voltage between terminals UDC+ and UDC- and the frame is close to 0 V.
• Never switch on the converter power supply while the reforming circuit is connected.
Lock the disconnector (if any) to an open position.
• Ensure that the converter is clean and dry (no condensation) before starting the
reforming.
In addition to the safety instructions given above, follow all safety instructions delivered
with the converter or given later in this manual. The complete safety instructions are given
at the beginning of the Hardware manual.
 Introduction 7

Reader
You are expected to know the standard electrical wiring practices, electronic components,
and electrical schematic symbols.
8 Introduction
 Reforming the capacitors 9

2
Reforming the capacitors

Method 1
Use method 1 for capacitor reforming if the converters have been stocked (non-
operational) for less than two years.
1. Switch the power on to the converter for the time indicated in section Reforming time
on page 13.
2. Do not load the converter while the reforming is ongoing.
The converter “wakes up” its capacitors on its own, after which it is ready for use.

Method 2 A
Use method 2 A or method 2 B (page 11) for capacitor reforming if the converters have
been stocked (non-operational) for two years or longer.

WARNING! Never switch on the converter power supply while the reforming
circuit is connected. Lock the disconnector (if any) to an open position.

WARNING! Only a qualified electrician is allowed to do the work. Read and follow
the instructions below. Neglecting the instructions may cause physical injury or
death.

1. Ensure that the converter module is disconnected from all possible power sources (all
AC and DC inputs/outputs are disconnected).
2. Ensure by measuring that the converter is dead (terminals U1, V1, W1, UDC+, UDC-,
U2, V2 and W2).
10 Reforming the capacitors

3. Compose a reforming circuit (see the diagram and data below) and connect it to the
DC terminals of the converter module.
4. Switch on the reforming circuit for the time defined in section Reforming time on page
13.
Note: Limit the reforming current to max. 500 mA. If the DC power supply does not
have an adjustable current limiter, increase the voltage gradually from 0 to a full scale
value.
5. Switch off the reforming circuit.
6. Wait for 5 minutes to let the converter DC capacitors discharge.
7. Ensure by measuring that the DC terminals of the converter are dead.
8. Disconnect the reforming circuit from the converter.
Regulated DC power with active current limiting:
• Output current: 0.5…1 A DC, max. 500 mA during reforming
• Output voltage: adjustable 0…1000 V DC. An appropriate voltage during reforming is
1.35…1.45·Ux. Ux denotes the nominal AC voltage of the converter.

WARNING! Capacitors may be damaged if excessive DC voltage is used during

reforming.

An external resistor is not needed if the DC power supply has an adjustable current limiter.

DC
DC power supply
Power supply
0.5 AA...1
0.5 ... 1AA1000
1000VVDC
DC

R = 100 Ohm / 500 W

Disconnect SUPPLY INVERTER

SUPPLY
UNIT UDC- UDC+ INVERTER
UNIT
W1 W2

Ux

V1 FREQUENCY V2
DRIVE MODULE
CONVERTER

U1 U2
 Reforming the capacitors 11

Method 2 B
Use method 2 B or method 2 A (page 9) for capacitor reforming if the converters have
been stocked (non-operational) for two years or longer.

WARNING! Never switch on the converter power supply while the reforming
circuit is connected. Lock the disconnector (if any) to an open position.

WARNING! Only a qualified electrician is allowed to do the work. Read and follow
the instructions below. Neglecting the instructions may cause physical injury or
death.

1. Ensure that the converter module is disconnected from all possible power sources (all
AC and DC inputs/outputs are disconnected).
2. Ensure by measuring that the converter is dead (terminals (U1, V1, W1, UDC+, UDC-,
U2, V2 and W2).
3. Compose a reforming circuit (see the diagram and table below) and connect it to the
DC terminals of the converter module.
4. Switch on the AC power supply of the reforming circuit for the time defined in section
Reforming time on page 13.
5. Switch off and disconnect the AC power supply of the reforming circuit.
6. Wait for 5 minutes to let the converter DC capacitors discharge.
7. Ensure by measuring that the DC terminals of the converter are dead.
8. Disconnect the reforming circuit from the converter.
12 Reforming the capacitors

Uxx
U

Disconnect SUPPLY INVERTER

SUPPLY UDC- UDC+ INVERTER
UNIT UNIT

W1 W2

Ux
Ux
V1 DRIVE MODULE
FREQUENCY V2
CONVERTER

U1 U2

Recommended components

A R C

200 V < U× < 240 V SKD 82/16 220 Ohm / 700 W 22 nF / 2000 V

380 V < U× < 415 V SKD 82/16 220 Ohm / 700 W 22 nF / 2000 V

380 V < U× < 500 V SKD 82/16 470 Ohm / 1200 W 22 nF / 2000 V

525 V < U× < 690 V SKD 82/16 680 Ohm / 1700 W 22 nF / 2000 V
 Reforming the capacitors 13

Reforming time
The intermediate circuit (DC link) of the converter is connected to its nominal voltage for
the reforming time to “wake up” the capacitors. The reforming time required depends on
how long the converter has been stocked (non-operational), as depicted in the following
diagram.

Capacitor reforming time

6

5
in hours

4
in hours
timetime

3
Forming

2
Reforming

0
0 1 2 3 4 5 6

Method
Method1 1 Method
Method2 2
Non-operational
Non-operationaltimetime
in years
in years
14 Reforming the capacitors
Further information
Product and service inquiries
Address any inquiries about the product to your local ABB representative, quoting the type
designation and serial number of the unit in question. A listing of ABB sales, support and
service contacts can be found by navigating to www.abb.com/drives and selecting Sales,
Support and Service network.

Product training
For information on ABB product training, navigate to www.abb.com/drives and select
Training courses.

Providing feedback on ABB Drives manuals

Your comments on our manuals are welcome. Go to www.abb.com/drives and select
Document Library – Manuals feedback form (LV AC drives).

Document library on the Internet

You can find manuals and other product documents in PDF format on the Internet. Go to
www.abb.com/drives and select Document Library. You can browse the library or enter
selection criteria, for example a document code, in the search field.
Contact us

3BFE64059629 Rev E (EN) 2012-03-21

ABB Oy ABB Inc. ABB Beijing Drive Systems Co. Ltd.
Drives Automation Technologies No. 1, Block D, A-10 Jiuxianqiao Beilu
P.O. Box 184 Drives & Motors Chaoyang District
FI-00381 HELSINKI 16250 West Glendale Drive Beijing, P.R. China, 100015
FINLAND New Berlin, WI 53151 Telephone +86 10 5821 7788
Telephone +358 10 22 11 USA Fax +86 10 5821 7618
Fax +358 10 22 22681 Telephone 262 785-3200 www.abb.com/drives
www.abb.com/drives 1-800-HELP-365
Fax 262 780-5135
www.abb.com/drives